Audi Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Tube -VW 418 A-

t	Press tool -VW 454-

t	Installing sleeve -VW 455-

t	Spacer sleeve -VW 472/2-

t	Thrust pad -VW 510-

t	Tube -30 - 14-

t	Press tool -40 - 21-

t	Thrust piece -3002-

t	Counterhold tool -3067-

t	Tube -3259-

t	Wheel bearing tube -3345-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t	-1-Internal puller 46...58 mm, e.g. -Kukko 21/7-

t	-4-Counter support, e.g. -Kukko 22/2-

t	Heat tapered roller bearing inner race to 100° C before installing.

t	Always renew both tapered roller bearings together.

t	Items 14, 15/16, 17 and 23 were modified from gearbox build date 06 05 2 → Chapter. Select correct components from → Electronic parts catalogue.

t	Adjust differential if tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed → Chapter.

1 -	Countersunk bolt

q

25 Nm

q	Screws into threaded piece → Item

2 -	Flange shaft (right-side)

q	Do not interchange; left and right flange shafts are different

3 -	Spring for flange shaft

q	Installed behind flange shafts

4 -	Thrust washer

q	Installation position: lip faces spring

5 -	Tapered ring

q	Installation position: Taper towards differential cage

6 -

Circlip

q	Holds tapered ring, thrust washer and spring in position when flange shaft is removed

7 -

Sun wheel

q	Installing → Fig.

8 -	Threaded piece

q	Installing → Fig.

9 -	Differential pinion pin

q	To remove, shear off spring pin → Item → Fig.

q	Installing → Fig.

10 -	Planet pinion

q	Installing → Fig.

11 -	One-piece thrust washer

q	Modified on some gearbox versions → Fig.

q	Lubricate with gear oil before installing

q	For correct version, refer to → Electronic parts catalogue

12 -	Flange shaft (left-side)

q	With dust plate

q	Do not interchange; left and right flange shafts are different

13 -	Flange shaft oil seal (left-side)

q	Different diameters for left and right

q	Renewing with gearbox installed → Chapter

14 -

Shim S1

q	For differential

q	Always 1 mm thick

q	Modification: adapted to enlarged tapered roller bearing on gearbox housing side → Chapter

q	For correct version, refer to → Electronic parts catalogue

15 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Modification: enlarged from gearbox build date 06 05 2 → Chapter

q	For correct version, refer to → Electronic parts catalogue

16 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

q	Modification: enlarged from gearbox build date 06 05 2 → Chapter

q	For correct version, refer to → Electronic parts catalogue

17 -	Differential cage

q	With final drive gear

q	Modification: adapted to enlarged tapered roller bearing on gearbox housing side → Chapter

q	For correct version, refer to → Electronic parts catalogue

18 -	Spring pin

q	For securing differential pinion pin

q	Is sheared off on removal → Fig.

q	Installing → Fig.

19 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

20 -	Tapered roller bearing outer race

q	Pressing out → Fig.

q	Pressing in → Fig.

21 -

Shim S2

q	For differential

q	Determining thickness → Chapter

22 -

Oil seal

q	For flange shaft (right-side)

q	Different diameters for left and right

q	Renewing with gearbox installed → Chapter

23 -	Gearbox housing

q	Modification from gearbox build date 06 05 2: enlarged bearing seat for tapered roller bearing/differential → Chapter

q	For correct version, refer to → Electronic parts catalogue

24 -	Clutch housing

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 46 ... 58 mm, e.g. -Kukko 21/7-

Pressing outer race for tapered roller bearing into gearbox housing –  Fit shim S1, always 1 mm thick, under outer race. –  Support gearbox housing with tube -3259- directly below bearing mounting.

Pulling off tapered roller bearing inner races –  Before fitting puller, position spacer sleeve -VW 472/2- and thrust piece -3002- on differential cage.   Note The procedure for pulling tapered roller bearing inner races off differential cage is the same for both bearings.

Pressing on tapered roller bearing inner races –  Support opposite side of inner race using -VW 455-.

Pressing tapered roller bearing outer race -A- out of clutch housing B -  Internal puller 46 ... 58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with tube for wheel bearing -3345- directly below bearing mounting.

Pressing out differential pinion pin The spring pin is sheared off when pressing out. –  Drive the remaining part of the spring pin out of the differential cage.

Modification of one-piece thrust washer and differential cage On some gearboxes, the one-piece thrust washer has a projection next to the holes -A-. In this case the differential cage has a corresponding circular slot -B-. –  Lubricate one-piece thrust washer with gear oil and install. –  Position one-piece thrust washer so that it engages in the slot -B- in the differential cage.

Installing differential bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Install both sun wheels and secure (e.g. with flange shaft). –  Insert planet pinions (180° apart) and pivot into position. –  Push differential pinion pin -arrow A- in as far as first planet pinion. –  Fit threaded pieces -arrows B- in sun wheels. Installation position: Stepped shoulder towards sun wheel –  Drive differential pinion pin into final position and secure with spring pin.